Driven Load-Bearing System

ABSTRACT

A hand- or voice-operated controller system for a driven loadable construct has a plurality of control circuit receiving inputs from a directional control and connection circuitry for communicating signals from the control circuit to at least one motor disposed on the loadable construct and to which at least one drive wheel disposed on the loadable construct is electrically coupled.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/804,015, filed Mar. 14, 2013, the entire disclosures of which areincorporated herein by reference in their entirety.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to driven, load bearing systems andmethods for constructing and using the same to move objects placed orstored thereon.

BACKGROUND

Constructs, such as pallets and skids, which may be used for thesupport, storage, and transportation of materials, are in widespreadusage. The most common types of pallets are constructed from wood,plastic, metal, or paper. Some pallets contain two decks made up from aplurality of longitudinally and laterally extending cross-board membersand block members. One or more connecting members hold the upper andlower decks together while distributing the cargo loads placed on theupper deck. Alternatively, those skilled in the art may use skids inplace of pallets.

In the art of material handling, transport devices such as pallet jacks,pallet trucks, end-rider trucks, and center trucks are wheeled devicesthat often incorporate a lifting mechanism intended for the manuallifting of a pallet, skid, dolly, or other loadable device. Where theloadable construct is a pallet, the load resting on top of the pallet,the pallet itself, and the transport device is moved from one work areato another. Once moved, the transport device disconnects from therecently transported pallet and is ready to grab or lift another palletand its load resting on top of the pallet to another location. Timelyand efficient transportation of cargo loads placed on the upper deck isvery important in manufacturing operations.

Present attempts to provide material transport mechanisms have resultedin relatively expensive and bulky devices that either grab or lift aload resting on a pallet along with the pallet itself. For example, ifthe force is significant, the tines of a fork-lifting truck makingcontact with the lead boards of the pallet decks and/or connectingmembers of a pallet can cause damage during alignment.

Therefore, it is desirable to provide a device that can combine thesupport and material storage capabilities of a loadable construct, suchas a pallet or skid with the transport capabilities of a pallet jack,pallet truck, end rider truck, or center truck.

SUMMARY OF THE INVENTION

The present invention includes a device comprising a loadable constructhaving an upper surface and a lower surface, the upper surface beingconfigured for carrying a load. The construct also has at least onedrive wheel disposed on the construct, at least one motor operativelycoupled to each of the at least one drive wheel, at least one powersource electrically coupled to the at least one motor, and a controlleroperatively coupled to the at least one motor and/or or the at least onepower source and configured to control movement of the at least onedrive wheel.

The present invention includes loadable constructs such as pallets orskids. Accordingly, it may be useful to combine the support and materialstorage capabilities of a loadable construct, such as a pallet, with thetransport capabilities of a pallet jack, pallet truck, end rider truck,or center truck to accomplish other tasks, such as preventing palletdamage caused by lifting devices intended for the lifting of a pallet.It may be also useful to eliminate cross-contamination in criticalmanufacturing and warehouse operations introduced by way of thetransport device having contact with materials transported to anothermanufacturing process, manufacturing operation, or storage location.

The present invention includes power sources such as batteries.Accordingly, it is also useful to provide a driven pallet whose powersource is rechargeable after hours of operation.

The present invention includes a controller that may be electronicallycoupled to the driven, loadable construct by wired, wireless, or othermeans and be embedded in one or more compact digital mediums such ascomputers, laptops, handheld telecommunication or other such devices.Accordingly, it may be useful to provide a driven loadable constructwhose movement forward, backward, left, or right at a desirable speedcan be either wirelessly directed or commanded through a connection witha control unit containing a pointing device such as a joystick,switches, or application running on a computer, mobile device, orinteractive display.

The present invention includes a method of retrofitting a construct tobe a driven loadable construct, comprising the steps of coupling atleast one motor to the construct, coupling at least one drive wheel tothe at least one motor, coupling at least one power source to the atleast one motor, and coupling a controller to either of the at least onemotor and/or the at least one power source. Accordingly, the controlleris configured to generate a signal to the at least one motor to drivethe at least one drive wheel and move the construct.

The present invention includes coupling a drive wheel to a motor by wayof gears, chain assemblies, belt assemblies, sprockets, or a combinationof these. It may be further useful to provide a smoothly operating,substantially vibration free, driven loadable construct, such as apallet, which substantially retains precision alignment between the gearattached to the drive motor and the driving gear attached to the hub ofthe drive wheel.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description and the accompanying, interrelated embodimentsexemplified in the following figures and drawings.

FIG. 1 illustrates an isometric and topographical view of an exemplaryloadable construct.

FIG. 1A illustrates a cross-sectional view of line A-A drawn in FIG. 1.

FIG. 1B illustrates a cross-sectional view of line B-B drawn in FIG. 1.

FIGS. 2 and 2A illustrate an exemplary loadable construct.

FIG. 3 illustrates an exemplary drive wheel assembly.

FIGS. 4A-B illustrate an exemplary drive wheel assembly in variouscoupled arrangements to exemplary loadable constructs.

FIG. 5 illustrates a side view of an exemplary driven loadableconstruct.

FIG. 6 illustrates an exemplary free wheel assembly.

FIG. 6A illustrates a cross-section view of line A-A drawn in FIG. 6.

FIG. 7 illustrates another side view of another exemplary drivenloadable constructs.

FIGS. 8A and 8B illustrate bottom views of exemplary driven loadableconstructs.

FIGS. 8C and 8D illustrate bottom views of other exemplary drivenloadable constructs.

FIG. 9A illustrates another side view of an exemplary driven loadableconstruct.

FIG. 9B illustrates another side view of another exemplary drivenloadable construct.

FIG. 10 illustrates exemplary controllers for an exemplary drivenloadable construct.

FIG. 11 illustrates an exemplary electrical schematic of an exemplarycontroller for an exemplary driven loadable construct.

In the drawings like characters of reference indicate correspondingparts in the different figures. The drawings are non-limiting examplesof the disclosed embodiments of the present invention and correspondingparts in the different figures may be interchanged and interrelated tothe extent such interrelationship is described or inherent from thedisclosures contained herein.

DETAILED DESCRIPTION

The disclosures set forth herein relate to systems for providingmovement to many forms of loadable constructs known to those skilled inthe art which can carry or bear a load on one of its surfaces. Anexemplary loadable construct may include but is not limited to pallets,skids, dollies, or bins.

FIG. 1 illustrates an exemplary loadable construct in the form of apallet 10 containing one or more components making up an upper deck 14,one or more components making up a lower deck 18, and connecting members16 coupling portions of upper deck 14 to portions of lower deck 18.While upper deck 14 and lower deck 18 may be shown as discrete portionsseparated by gaps, any suitable arrangement of components to make up anupper deck 14 or lower deck 18 of a pallet 10 may be utilized.Similarly, while connecting member 16 may be illustrated as beingperpendicular to the components of upper deck 14 and/or lower deck 18,connecting member 16 may be arranged in any suitable fashion.

Pallet 10 has a face 11 and a side 12. An exemplary face 11 of arectilinear pallet may be the boundary of the pallet 10 where thecomponent of upper deck 14 most distal from the center of pallet 10 isarranged perpendicularly with the edge of connecting member 16 mostdistal from the center of pallet 10. An exemplary side 12 of arectilinear pallet may be the boundary of the pallet 10 comprised of themost distal edge of the connecting member 16 that is most distal fromthe center of pallet 10 and is parallel to all other connecting members16. Upper deck 14 may receive a load on its surface to be transportedwith the remainder of pallet 10. While the exemplary components andarrangement of components as illustrated in FIG. 1 may be referred to inother related figures and disclosures, an exemplary pallet 10 may becomprised of any number and arrangement of components known to thoseskilled in the art.

Referring to FIG. 1A, an exemplary profile view of face 11 may showupper deck 14 separate from lower deck 18 by one or more connectingmembers 16. The space separating upper deck 14 from lower deck 18 inwhich no portion of connecting member 16 occupies is pallet space 17.Where connecting member 16 is hollow or perforated, such a perforationor hollow opening may be illustrated as aperture 2. While FIG. 1A mayshow aperture 2 as rectilinear in cross section, aperture 2 may be anysize or shape suitable for use in an exemplary connecting member 16.

Referring to FIG. 1B, an exemplary upper deck 14 may be comprised of aplurality of members separated by channels 15 to form a substantiallycorrugated pattern atop connecting members 16. Opposite upper deck 14,lower deck 18 may be comprised of a plurality of members separated bychannels 19 to form a substantially corrugated pattern below connectingmembers 16. According to the exemplary embodiment of FIG. 1B, eitherupper deck 14 or lower deck 18 may be made of multiple components or asingle component depending on the manufacture of the two parts of pallet10. For instance, upper deck 14 and/or lower deck 18 may be formed of asolid material and cut to form various ribs that provide for acorrugated-like pattern above or below connecting members 16.Alternatively, upper deck 14 or lower deck 18 may be formed withoutchannels 15 or 19.

Additionally, while shown in FIG. 1B as a contiguous piece of material,connecting member 16 may also be comprised of discrete portions withgaps interposed between the portions. In one exemplary embodiment,connecting member 16 may be divided into two or more blocks and placedat the edges and center portions of upper deck 14 and/or lower deck 18.In another exemplary embodiment, connecting member 16 may be dividedinto a multiple rows of blocks arranged in any fashion to maximize thecarrying potential and load bearing capabilities of pallet 10. The size,shape, placement and arrangement of the various component parts andpieces of upper deck 14, lower deck 18, and connecting members 16 can beoptimized for a particular application according to the knowledge ofthose skilled in the art.

An exemplary pallet 10 may be comprised of upper deck 14, lower deck 18,and connecting members 16 formed of any suitable material known to thoseskilled in the art, including plastic, wood, metal, paper, rubber, orany other materials capable of sustaining loads from subject matterplaced thereon. An exemplary pallet 10 may be assembled by screws,nails, heat molding, adhesives, fasteners, welding, or any othermechanical, chemical, electrical, or other suitable fabrication methodsknown to those skilled in the art.

In a preferred embodiment, pallet 10 may be a conventional wooden pallethaving the industry standard size and dimensions, which are currently 40inches wide by 48 inches long (1.0 m by 1.2 m). According to thepreferred embodiment, upper deck 14 may be secured to lower deck 18 bybolts, screws, nails, rivets, or other mechanical fasteners goingthrough the surfaces of the decks 14/18 and into the surface of member16. Other specifications for pallets may be readily determined bypersons of skill in the art for use in a particular application. Forexample a wooden pallet may be 42 inches by 42 inches for communicationsequipment and paint, 40 inches by 48 inches for military and cementshipments, 36 inches by 36 inches for chemical drums, and 48 inches by36 inches for shingles. These and other specifications are found anddescribed in the Uniform Standard for Wood Pallets from the NationalWooden Pallet and Container Association, Alexandria, Va., which isincorporated herein by reference in its entirety.

With reference to FIG. 2, another type of exemplary loadable constructmay be a skid 20. Skid 20 may be cut, extruded, carved, or otherwiseformed from a single piece of material, such as steel, aluminum, wood,plastic, paper, rubber, cast iron, brick, or titanium. Skid 20 may havea front 21 and a back 23. Skid 20 may be formed in any shape orconfiguration for given applications. In a preferred embodiment, skid 20is an octagon-shaped portion of an aluminum alloy.

With reference to FIG. 2A, a top surface 20A of skid 20 may be comprisedof surface abrasions, textures, or other contours for aid in holding aload. A bottom surface 20B may be similarly formed like top surface 20A,but may otherwise be smooth. In an exemplary embodiment according toFIGS. 2 and 2A, skid 20 may be bent or molded to retain certain sizedloads or advantageously concentrate weight on certain parts of the skid20.

According to the illustrative embodiment of FIG. 3, a drive wheelassembly 30 may be comprised of a wheel frame 31 and a drive wheel 38which may be driven by rotation of a drive shaft 32. A driven gear 34mounted to drive shaft 32 via gear mount screw 29 may rotate drive gear36 coupled to drive wheel 38. Drive wheel 38 and gear 36 rotate aboutaxles 22 and 24, respectively, which are both coupled to axle end 26 andaxle mount 28. Drive wheel 38 and gear 36 are disposed about axle 22 and24 by virtue of an axle washer or spacer 25/27. While axle runningthrough drive wheel 38 has been illustrated in sections, it may beunderstood that the several axle segments 22/24/26 may comprise a singleaxle.

An exemplary wheel frame 31 may be shaped or formed from any suitablematerial, such as a metal or plastic, to withstand the rotational forcesresulting from drive shaft 32, gears 34 and 36, drive wheel 38, andaxles 22, 24, and 26. An exemplary wheel frame 31 may also be shaped orformed from any suitable material to withstand the load forces andpressure of a loadable construct coupled to the wheel frame's exteriorsurface. A wheel frame 31 may be a solid metal bracket with openings forthe various moving parts of the drive wheel assembly 30. While gears 34and 36 are illustrated, any number of gears may be utilized to rotatedrive wheel 38 in a given application. A person of ordinary skill in theart may vary the size, gear ratio, and material of a particular gear toprovide optimized rotational capabilities to an exemplary drive wheel38. According to another embodiment of an exemplary driven wheelassembly 30, gears 34/36 may be replaced with a chain drive andsprocket, or belt and pulley system. Further, a properly sized gear 34may rotate drive wheel 38 directly without an intervening gear 36, forexample, by the use of a properly-sized drive gear 34.

In addition, any drive wheel assembly 30 or free wheel assembly 40 maybe engineered to be either fixed or steerable dependent on the specificsize, physical shape, material, loading characteristics, and design ofthe construct being either retrofitted or manufactured. Differentdiameter caster wheels 48 may be required. Additionally, variousdiameter drive wheels 38 may be used requiring a different gearreduction. Alternatively, a direct gear drive can be replaced by a beltor chain drive system.

An exemplary drive wheel 38 may be made out of rubber or metal (forreception on a rail or to hold a belt track). When coupled to a loadableconstruct, such as a pallet 10 or skid 20, an exemplary drive wheel 38may be sized and shaped to accommodate the loads placed upon a loadableconstruct such as pallet 10 or skid 20 to move pallet 10 or skid 20while holding such loads. In an exemplary embodiment illustrated by FIG.3, a collar 28 may be affixed to each end of axle 22. Collar 28 may holdaxle 22 fixed securely by way of collar screws through collar 28 andthrough wheel frame 31 (not shown). Additional screws may hold collar 28fixed securely against wheel frame 31 facing a motor 50 (not shown).Spacers 25 and 27 may be placed between each end of drive wheel 38.

Referring to FIGS. 4A and 4B, an exemplary drive wheel assembly 30 maybe coupled to a loadable construct, such as pallet 10, in a variety ofways. Drive wheel assembly 30 may be coupled to pallet 10 via its wheelframe 31. In FIG. 4A, wheel frame 31 may be bolted to lower deck 18 byuse of mechanical coupling mechanism 5. An exemplary mechanical couplingmechanism 5 may include bolts, screws, clamps, and fasteners.Additionally, the same or similar mechanical, chemical, or alternativecoupling mechanisms known to those skilled in the art usable to couplean exemplary upper deck 14, lower deck 18 and member 16 together as anexemplary pallet 10 may also be used for coupling an exemplary drivewheel assembly 30 to an exemplary pallet 10. For example, wheel frame 31may be screwed into lower deck 18 or a combination of lower deck 18 andmember 16. In an exemplary embodiment, a bolt or screw which attacheswheel frame 31 to pallet 10 may breach the inner surface of a hollowmember 16 and be capped, bolted, or otherwise made to lock in the drivewheel assembly 30 to the lower deck 18 of pallet 10. In a furtherexemplary embodiment, drive wheel assembly 30 may be coupled to pallet10 on its faces/sides 11/12 or a combination of pallet faces, sides, anddecks.

With reference to FIG. 4B, wheel frame 31 may be further configured forattachment to other locations on a loadable construct by extensionbracket 33. Extension bracket 33 may provide additional locations ofcoupling wheel frame 31 to pallet 10, for instance, within the channels19 of lower deck 18 and/or within the pallet spaces 17 of pallet 10. Anexemplary extension bracket 33 may be similarly coupled to wheel frame31 through bracket couplers 7, which would be understood by persons ofordinary skill in the art to encompass all known mechanical and chemicalcouplings, such as, for example, bolts, screws, welds, rivets, andclamps. Bracket 33 may itself be coupled to pallet 10 by being situatedand coupled across channels 19 in lower deck 18, being situated betweenlower deck 18 and upper deck 14 and coupled to one or the other, orbeing situated and coupled on or within connecting member 16. Couplingmechanisms 6 exclusively hold bracket 33 to pallet 10 and indirectlyretain wheel frame 31 to pallet 10 by virtue of its coupling to bracket33. An exemplary wheel frame 31 and/or bracket 33 may be coupled topallet 10 directly and indirectly, simultaneously, using couplers 5, 6,and 7 for added strength or rigidity. Bracket 33 may be made out of thesame or similar material as wheel frame 31 and can be configured toadapt drive wheel assembly 30 to any portion of pallet 10.

Referring to the illustrative embodiment of FIG. 5, a plurality of drivewheel assemblies 30 may be coupled to a loadable construct, such as apallet 10 or skid 20, to form a driven loadable construct (“DLC”) 100.In an exemplary DLC system 100, the loadable construct used may be apallet 10, the drive wheels 38A and 38B may be mounted to a wheel frame31 by axles 22, 24, and 26, and they may be driven by the operativecoupling of drive gears 36 and 34 and motor drive shaft 32. Again, whileaxles 22, 24, and 26 denote separate sections of a complete axle runningthrough wheel frame 31, a unitary axle may be composed of each of thesections 22, 24, and 26 integrated together.

An exemplary drive shaft 32 may be driven by a motor 50 coupled to aloadable construct, such as a pallet 10 or skid 20, by a variety ofcoupling mechanisms known to those skilled in the art. An exemplarystructure to couple motor 50 to pallet 10 may be a motor cradle 55.Alternatively, as shown in the exemplary embodiment illustrated in FIG.5, drive wheel 38B may be driven by an operable arrangement of drivegears and shafts by a motor 50 mounted directly to the loadableconstruct, which may be a pallet 10. In another alternative exemplaryembodiment, drive wheels 38A or 38B may be driven by a belt and pulleyor chain and sprocket system connected to motor 50 in substitution forgears 36 and 34. An exemplary motor 50 may be any suitable motiondelivery system suitable for the applications of carrying loads placedupon pallet 10 and to move the same.

In a preferred embodiment, motor 50 may be a permanent magnet motor ofthe type sold and manufactured by Leeson Electric Corporation ofGrafton, Wisc. In yet another preferred embodiment, motor 50 may run on24 Volts, provide 1/10 Horsepower, and provide 15 lb-in of torque at 300RPM. Additionally, 12 volt pancake motors from PMI Motion Technologiesof Commack, N.Y. may be utilized to reduce the space occupied byotherwise longer and cylindrical motors. Other potential motorcandidates also include DC motors and parallel shaft gearmotors from RAECorporation of McHenry, Ill.

Where the loadable construct is a pallet 10, an exemplary motor cradle55 may be coupled to the lower deck 18 of pallet 10 by one or more ofthe following: cradle floor 51, drive shaft panel 54, cradle wall 52,and/or cradle top 53. While motor cradle 55 may be illustrated as arectilinear construct in FIG. 5, motor cradle 55 and any of cradle floor51, drive shaft panel 54, cradle wall 52, and/or cradle top 53 may beshaped or configured in any way known to those skilled in the art tosupport an exemplary motor 50.

Motor cradle 55 and any of cradle floor 51, drive shaft panel 54, cradlewall 52, and/or cradle top 53 may be made of the same material as wheelframe 31, wheel section 44 (as shown and described with reference toFIGS. 6 and 6A), body section 42 (as shown and described with referenceto FIGS. 6 and 6A), or bracket 33. Similarly, motor cradle 55 may becoupled to pallet 10 in the same or similar manner as wheel frame 31,body section 42 (as shown and described with reference to FIGS. 6 and6A), wheel section 44 (as shown and described with reference to FIGS. 6and 6A), or bracket 33.

In an exemplary embodiment, motor 50 may be supported by a combinationof drive shaft panel 54, wheel frame 31 and lower deck 18. In this way,motor 50 may be suitably supported with a reduction in parts to reducethe weight of an exemplary DLC 100. Alternatively, drive shaft panel 54may be integrated or one in the same with wheel frame 31. According tosuch an alternative embodiment, motor 50 may be suitably supported witha reduction in parts to reduce the weight of a DLC, such as a drivenpallet 100. An exemplary cradle wall 52 may be perforated or containgaps to allow passage of control circuitry 65 between motor 50 and apower source 60.

Power source 60 may be a battery, power cell, or group of power cells orbatteries capable of powering an exemplary motor 50. In a preferredembodiment, power source 60 may be a rechargeable battery fromPower-Sonic Corp. of San Diego, Calif. For example, power sources 60 mayalso be rechargeable, and a suitable recharger cable or cord (not shown)may be utilized to recharge such a power source 60 as is known to thoseskilled in the art. Accordingly, a recharge cord for an exemplaryrechargeable power source 60 may be stored on DLC 100 by means of hooks,grips, Velcro, recoiling mechanisms, or other holding devices for cordsknown to those skilled in the art.

An exemplary power source 60 may be supported by a power source cradle42, which may be similar in form and construction to motor cradle 55.Power source cradle 42 may be coupled to pallet 10 in the same orsimilar manner as wheel frame 31, body section 42, wheel section 41,bracket 33, or motor cradle 55. In an exemplary driven pallet system100, power source 60 and power source cradle 42 may be mechanicallyconnected to lower deck 18 via couplings 6. Exemplary couplings 6 forcoupling power source 60 or power source cradle 42 may comprise the sameor similar coupling mechanisms known to those skilled in the art,including bolts, screws, rivets, welds, and clamps, which may also beused for coupling wheel frame 31 to pallet 10 or upper deck 14, lowerdeck 18 or connecting member 16 to one another to make up pallet 10.

Power source cradle 42 may substantially cover all of power source 60 ormay alternatively provide exposure of power source 60 to the ambient. Inthe alternative embodiment, an exposed power source 60 may benefit fromambient cooling when in operation. However, those skilled in the art mayselect power sources 60 which are suitable under the circumstances butwould operate sufficiently regardless of ambient exposure.

In an alternative embodiment illustrated in FIG. 5, drive wheel assembly30 may be comprised of a drive wheel 38B operably coupled for beingdriven by axles 22, 24, and 26 to drive gears 34 and 36, and drive shaft32 to a mountable motor 50. An exemplary mountable motor 50 may bemountable to pallet 10 in the same or similar way as wheel frame 31 orwheel frame 31 in combination with bracket 33. For example, an exemplarymountable motor 50 may have openings for insertion of screws, bolts, orthe like to secure motor 50 to pallet 10. Alternatively, mountable motor50 may be shaped and sized to be received in one or more channels 19 inlower deck 18, or pallet spaces 17 of pallet 10. Like motor 50,mountable motor 50 may be electrically coupled to power source 60 viacontrol circuitry 66.

Exemplary control circuitry 65 and 66 may be wire leads, cables, plugs,or any form of electrical leads known to those skilled in the art thatprovide for power from power source 60 to reach an exemplary motor 50.In one embodiment, control circuitry 65/66 may be free and unrestrainedunder pallet 10. In an alternative embodiment, control circuitry 65/66may be restrained to the bottom of pallet 10 by use of adhesives, tapes,staples, screws, fasteners, or other mechanisms known to those skilledin the art to prevent substantially free movement of control circuitryduring operation of driven pallet 100.

In a preferred embodiment, mounted on the hub of drive wheel 38 isninety-six tooth driven gear 36 being fixedly secured by severalmounting screws (not shown) to drive wheel 38. Mounted to the shaft 32of a direct current motor 50 is forty-two tooth driven gear 34.Forty-two tooth driven gear 34 is held in place on the shaft 32 of motor50 by way of setscrew 29. Driven gear 34 and drive gear 36 work incombination to provide a reduction ratio of 2.2857. The particular typeof gear structure selected permits direct rotation of drive wheel 38 ata speed which is appropriate for an operator walking besides anexemplary driven, loadable construct such as a pallet 10. Furthermore,the gear structure is selected to operate with direct current motor 50in such a manner that sufficient power is delivered to rotate drivewheel 38 to transport fully loaded pallet 10 up a relatively steepincline. Two pairs of fixed drive wheel assemblies 30 are designed tomove an 800 pound pallet load at three miles per hour on a flat surfacefor 3 hours before battery recharging is required. According to theaforementioned preferred embodiment, the power source consists of twopairs of 12-volt 26 ampere-hour batteries from Power-Sonic Corporationof San Diego, Calif. According to the preferred embodiment, a first pairof batteries are connected in series to yield 24-volts to power one setof drive wheels while another pair of batteries are connected in seriesto yield 24-volts to power an additional set of drive wheels.Alternatively, other arrangements of batteries may be utilized to powera drive wheel assembly 30 in accordance with the other teachings of therelated embodiments disclosed herein.

According to the illustrative embodiments of FIGS. 6 and 6A, anexemplary free wheel assembly 40 may comprise a wheel section 41 and abody section 42. An exemplary wheel section 41 may comprise a wheel 48within a wheel brace 44 and rotating therein about axle 46. Wheelsection 41 may be rotatably coupled to body section 42 by a revolutejoint 43, which may comprise a swivel, a ball bearing, or a rotatableshaft. Alternatively, wheel section 41 may be directly coupled to bodysection 42 while a ball wheel 48 may be used. According to thisalternative embodiment, ball wheel 48 would sit within a socket 41.Other wheel types and free wheel couplings known to those skilled in theart may be placed between wheel section 41 and body section 42 thatpermit substantially free range of motion of wheel section 41.

Free wheel assembly 40 contains a body section 42 which may be composedof several parts, 45A, 45B, 45C, and 45D. An exemplary body section 42may be made of any suitable material for a particular loadingapplication, such as, for example, metals. In an exemplary embodiment,body section 42 may be an open rectangular box-like structure made oftop 45A and bottom 45B and side-walls 45C and 45D. In another exemplaryembodiment, the parts of body section 42 may be sized and spacedaccordingly to accommodate a power source 60 disposed therein. Anexemplary free wheel assembly 40 may have a top 45A and a bottom 45Bwhich are single pieces of material and side-walls 45B and 45C whichcontain openings or spaces to reduce the amount of material used in theside-walls or to provide adaptability for power source 60. Further, eachof the parts 45A, 45B, 45C, and 45D may be interchangeable or replacedwith other such parts to accommodate different power sources 60,different free wheels 48, different wheel sections 41, different drivewheel assemblies 30, and/or different loadable constructs, such aspallets 10 or skids 20.

Top 45A of free wheel 40 may be coupled to a loadable construct, such aspallet 10 or skid 20, by any of the same coupling mechanisms describedabove with respect to drive wheel assembly 30 or upper deck 14, lowerdeck 18, and connecting member 16. Similarly, each of top 45A,side-walls 45C and 45D, and bottom 45B may be coupled in similar fashionto each other as may be other components making up pallet 10, drivewheel assembly 30, or pallet 10 incorporating drive wheel assembly 30.

According to the illustrative embodiment of FIG. 6A, free wheel 40 maybe held by a triangulated wheel brace 44 that may rotate freely viarevolute joint 43. While wheel brace 44 may be triangulated, it may beany shape or size which permits clearance of rotation of wheel 48 when aload is applied and can sustain such load forces without disrupting theaxle about which wheel 48 rotates. Body section 42 may be shown holdinga power source 60 within its walls 45C/D.

According to the illustrative embodiment of FIG. 7 where an exemplaryDLC involves a pallet 10, pallet 10 may be coupled to a pair of drivewheel assemblies 30A and 30B via couplings 5. A designated motor 50A anda designated motor 50B may provide rotation to drive the components ofdrive wheel assemblies 30A and 30B, respectively. Free wheel assembly 40may be disposed between drive wheel assemblies 30A and 30B and coupledto pallet 10 via couplings 6. An exemplary free wheel assembly 40according to the illustrative embodiment of FIG. 7 may contain a body 42housing power source 60 and simultaneously provide rotatable coupling ofwheel section 44 via revolute joint 43, which in turn, allows rotationof the operable assembly of wheel section 44, wheel 48, and axle 46.According to this embodiment, power source 60 may be dedicated to one ormore motor 50. Alternatively, power source 60 may be the dedicated powersource of only one of the motors 50A. As such, power source 60 mayelectrically couple to motor 50A by control circuitry 70 while motor 50Belectrically couples to an alternative power source (not shown) viacontrol circuitry 71.

Where the loadable construct illustrated by FIG. 7 is a pallet 10, anexemplary driven pallet 100 may have a set of driven wheel assemblies30A and 30B and an adequately positioned free wheel assembly 40. Such atriad arrangement of moving components may be utilized to move a pallet10 carrying a load from one location to another by activating the motors50A and 50B in order to rotate the wheels of the wheel assemblies 30Aand 30B. By applying power to only one motor among motors 50A or 50B maypermit for pivoting of DLC 100 through the use of free wheel assembly 40and the selected stationary driven wheel. For example, a triangulararrangement of wheel assemblies 30 and wheel 40 may be deemed sufficientfor use of a DLC 100. Alternatively, applying power to both motors 50Aand 50B so that each wheel rotates in opposite directions may permit forpivoting of DLC 100 through use of free wheel assembly 40. While a triadof moving components are illustrated in the exemplary embodiment of FIG.7, additional number and arrangements of free wheel assemblies anddriven wheels may be coupled to pallet 10 to provide for a suitabledriven pallet 100 for a given application.

Referring to FIGS. 8A, 8B, 8C, and 8D, a variety of DLCs are shown.Where an exemplary DLC is a driven pallet 100, it may have variousarrangements of driven wheel assemblies 30, free wheel assemblies 40,motors 50, and power sources 60. According to the exemplary embodimentillustrated in FIG. 8A, a driven pallet 100 may comprise four drivenwheel assemblies 30 powered by their respective motors 50 and sharingone or more power sources 60 via control circuitry 65. According to theillustrative embodiment of FIG. 8A, drive wheel assemblies 30 may becoupled on and across more than one component of lower deck 18 to securedrive wheel to pallet 10. Each drive wheel assembly 30 is parallel tothe side 12 of driven pallet 100 and may be separated from its adjacentdrive wheel assemblies 30 over the length of side 12 or over the lengthof face 11. According to the illustrative embodiment of FIG. 8A, powersources 60 may be coupled to lower deck 18 of driven pallet 100 by oneor more power source cradle components (not shown) disclosed withrespect to FIGS. 5, 6, 6A and 7. Alternatively, as shown in theillustrative embodiment of FIG. 8B, drive wheel assemblies 30 may beperpendicular to side 12 of DLC 100 while being separated from oneanother about the length of side 12. According to this alternativeexemplary embodiment, a pair of free wheel assemblies 40 may be disposedbetween the pair of drive wheel assemblies 30 and placed perpendicularlyto side 12 of DLC 100.

According to the illustrative embodiment of FIG. 8B, free wheelassemblies 40 may be coupled to DLC 100 in any fashion described herein.In the illustrative embodiment of FIG. 8B, free wheel assemblies 40 alsoserve as housings for power sources 60 which are dedicated to one of themotors 50 driving wheels of drive wheel assemblies 30. Each individualpower source 60 electrically couples to its respective designated motor50 via control circuitry 70. While as illustrated drive wheel assemblies30 approach the edge of pallet DLC faces 11 and free wheel assemblies 40are located closer to the center of DLC 100, it should be understoodthat the arrangement of these various moveable components of DLC 100 maybe made to accommodate the loads to be held by DLC 100, the distancesand terrain to be traversed by DLC 100, or a combination of these andother factors known to those skilled in the art.

With regard to the illustrative embodiments of FIGS. 8C and 8D where theDLC is a driven skid 200, a driven skid 200 may be one which utilizesdrive wheel assemblies 30, power sources 60, and free wheel assemblies40 on a skid 20 made out of a solid piece of material, for example, ofthe types and kinds described with respect to FIG. 2. Alternatively, inthe illustrative embodiment of FIG. 8C, an alternating arrangement ofdrive wheel assembly 30 and free wheel assembly 40 may be appropriatelyplaced about the underside of skid 200. According to the illustrativeembodiment of FIG. 8C, free wheel assembly 40 may house power source 60which is dedicated to one of the motors 50 driving a wheel of respectivedrive wheel assembly 30. Control circuitry 70 may electrically couplepower source 60 to its dedicated motor 50. According to the illustrativeembodiment of FIG. 8D, driven skid 200, like the driven pallet 100 ofFIG. 8A, may be comprised of at least one driven wheel assembly 30connected to one or more shared power sources 60. As illustrated, powersource 60 may service the power needs of motor 50 of each of the drivewheel assemblies 30 via control circuitry 65. According to theillustrative embodiment of FIG. 8D, power source 60 may be sized toadequately power one or more of the shared motors 50 used to operatedrive wheel assemblies 30. In contrast to the abovementioned triad ofdrive wheel assemblies 30, the illustrative embodiment depicted by FIG.8D comprises a triad of free wheel assemblies 40 surrounding at leastone drive wheel assembly 30. A motor 50C may be utilized to rotate arevolute gear assembly 78 coupling drive wheel assembly 30 to underside20B of driven skid 200. Accordingly, controlled rotation of theoperative combination of drive wheel assembly 30 and motor 50 may beachieved by motor 50C. Motor 50C may drive revolute gear assembly 78 toallow for pivoting movement of driven skid 200.

In a preferred embodiment, a wooden pallet 10 may be mounted to a steelskid 20 to maximize distribution of weight of a load on the supportingwheel assemblies 30 and/or 40. Alternatively, an exemplary wheelarrangement for a DLC 100/200 may seek to establish a low center ofgravity for device stability. Accordingly, an exemplary DLC 100/200 mayhave all device components, such as motors, power sources, andmotivation equipment stored within a driven component (such as drivenskid 200) while the non-driven component (pallet 10) is mounted abovethe driven component without any of the device components stored withinor on it.

According to the illustrative embodiment of FIG. 9A, a DLC, such as adriven pallet 100, may be supported by a series of drive wheelassemblies 30 and a series of free wheel assemblies 40, each coupled topallet 10 via coupling mechanisms 5 and 6, respectively. As illustratedin FIG. 9A, drive wheel assemblies 30A may be coupled across a channel19 of lower deck 18 by its wheel frame 31A with separate couplings indifferent portions of lower deck 18. Motor 50A may operate drive wheelassembly 30A and may be coupled around lower deck 18 and/or withinchannel 19, as illustrated, by an appropriately configured wheel frame31A, or via a combination of wheel frame 31A and a coupled- orintegrated-bracket 33. According to the exemplary embodiment of FIG. 9A,motor 50A may be sized or held by appropriate motor cradle 55 or othermotor cradle components (not shown) to remain in operable connectionwith drive wheel assembly 30A. Motor 50A may be driven by one or morepower sources (not shown) that are on the opposite side of free wheelassembly 40.

As illustrated in FIG. 9A, an exemplary DLC 100 may comprise a freewheel assembly 40 containing a wheel base 44 holding free wheel 48 and abody section 42 housing a power source 60 dedicated to powering a motor50B. Free wheel assembly 40 may be sized and shaped to be coupled tolower deck 18 of pallet 10 by one or more coupling mechanisms 6, such asbolts, clamps, screws, or other coupling mechanisms known to thoseskilled in the art and disclosed herein.

As further illustrated in FIG. 9A, an exemplary drive wheel assembly 30Bmay be driven by motor 50B powered by its dedicated power source 60 heldin free wheel assembly 40. Drive wheel assembly 30B and wheel frame 31Bmay be substantially different from drive wheel assembly 30A and wheelframe 31A, respectively, in shape and size and may be coupled to pallet10 at various points in upper deck 14, connecting member 16, and/orlower deck 18 by one or more coupling mechanisms 5. According to theexemplary embodiment illustrated in FIG. 9A, a driven pallet systeminvolving DLC 100 may benefit from interchangeable modularity of themoveable components such as drive wheels and free wheel assemblies. Inthis way, an exemplary DLC 100 may have the ability to receive furtherdrive wheels similar or related to drive wheel assemblies 30A and/or 30Band further free wheel assemblies 40 for any particular application.

With reference to the illustrative embodiment of FIG. 9B, a DLC, such asdriven skid 200, may be made from a uniform construct pallet 20, may besupported by an assortment of drive wheels, such as drive wheelassemblies 30A, 30B, or 30C and free wheel assemblies 40. As illustratedin FIG. 9B, an exemplary driven skid 200 may rest atop a drive wheel 38Aoperatively coupled within or on a wheel frame 31A which is then coupleddirectly or indirectly through a bracket via couplings 5 to underside20B of skid 20. Drive wheel assembly 30A may be driven by motor 50Awhich may be coupled to the underside of skid 20 directly or withassistance from a motor cradle 55 (not shown). This type of drive wheelassembly 30A may be substituted for any other drive wheel assemblies 30disclosed in the various embodiments to suit the purposes of the palletto which they are coupled.

An exemplary driven skid 200 may also comprise a free wheel assembly 40disposed between drive wheel assemblies 30A and 30C, and like free wheelassembly 40 in FIG. 9A, may also house power source 60. Free wheelassembly 40 may couple to skid 20 via couplings 6 under or through skid20 to body part 42. In an exemplary driven skid 200, drive wheelassembly 30C may be frictionally or slidingly engaged on skid 200 onboth its top surface 20A and underside 20B. According to the exemplaryembodiment of FIG. 9B, an exemplary wheel frame 31C of drive wheelassembly 30C may be configured to be held substantially in place on skid20 when a load is applied to surface 20A. By virtue of forces from theload, skid 20 may maintain frictional contact with the mouth formed bywheel frame 31C and hold drive wheel assembly 30C in place. An advantageof such a drive wheel assembly 30C may be the ready attachment anddetachment from a loadable construct, such as a skid 20. A drive wheelassembly 30C may be substituted for any of the drive wheel assemblies 30disclosed herein. Drive wheel assembly 30C may be driven by motor 50Beither by electrical contact through wired hook-up or through aplug-and-play type of configuration in which an exemplary drive wheel30C may be lodged on loadable construct in a manner that substantiallybrings its driven wheel in contact with motor 50C. Either one or both ofmotors 50A and 50B may be electrically coupled to and powered by powersource 60. Alternatively, each of motors 50A and 50B may have dedicatedpower sources 60 housed in either free wheel assemblies 40 or elsewhereon pallet 10 or 20, as shown in FIGS. 8A, 8B, 8C, and 8D.

In a preferred embodiment, two pairs of fixed drive wheels 30 aresecurely fastened beneath lower deck 18 of pallet 10 with mounting bolts5 at respectively adjacent opposite ends. Drive wheel assembly 30contains eight inch diameter drive wheels 38, motor cradle 55, and adirect current brushed motor 50 rated at twenty-four volts. The size ofthe motor will typically be about 3.5 inches in diameter with a lengthof between two to five inches depending on the power desired. Directcurrent brushed motor 50 is fixed securely by mounting screws 5 to motorcradle 55. Drive wheel 38 is rotatable solely within a plane of rotationaround axle 22 which is mounted to wheel frame 31 via axle portion 26.Turning of the driven pallet 100 left or right is accomplished byrotating each pair of drive wheels 38 in opposite directions. The drivenpallet 100 can be made to move forward or backward by turning each pairof drive wheels 38 in the same forward or reverse direction. The directdrive structure provided by gear reduction and independent motors 50allows for precise control and a low-turning radius for steering thepallet 100.

In another preferred embodiment, a cost reduction is achieved byreplacing one pair of drive wheel assemblies 30 with two, less-expensivefree-rolling caster wheel assemblies 40 containing five inch diametercaster wheels 48. As shown in FIGS. 7, 8B, 8C, 9A, and 9B, each casterwheel assembly 40 is securely fastened to lower deck 18 of pallet 10 orsecurely fastened to underside 20B of skid 20 with mounting bolts 6.Eliminating one pair of drive wheel assemblies 30 allows for furthercost reduction by reducing power requirements to drive wheels 38.According to this preferred embodiment and with reference to FIG. 11,the power source 60 consists of two twelve volt gel type batteries. Inthis embodiment two twelve volt batteries are connected in series andare used to supply operating voltage for two direct current, twenty-fourvolt motors 50. According to the aforementioned preferred embodiment,two pairs of drive wheel assemblies 30 are designed to move an 800 poundpallet load at three miles per hour on a flat surface for 3 hours beforebattery recharging is required. While four twelve volt batteries havebeen illustrated, those skilled in the art may recognize reduction orincrease in the number of batteries depending on any of the designconsiderations disclosed herein. For example, where only two drivenwheel assemblies 30 are to be used, an exemplary driven pallet 100 ordriven skid 200 may require only two batteries instead of four.

As disclosed, an existing loadable construct such as conventional wood,metal, paper, or plastic pallet 10 can be retrofitted so that it becomesdriven. Also, a skid 20 may also be manufactured to accommodate thecoupling of driving components as described herein. This is accomplishedby attaching a power source 60, motor drive circuitry (as may beillustrated and described with respect to FIG. 11), power sourcerecharge circuitry (as may be illustrated and described with respect toitems 1020 and 1070 of FIG. 11), at least one motor 50 for producingrotational energy, and a combination of one or more drive wheelassemblies 30 and, optionally, one or more free wheel assemblies 40 to aconventional wood, metal, paper, or plastic pallet 10. In addition,rotational energy from at least one motor 50 may be controllably coupledto at least one drive wheel assembly 30. The number of drive wheelassemblies 30 and free wheel assemblies 40 required in order to movepallet 10 forward, backward, left, or right at a desirable speed maydepend on the specific size, physical shape, material, loadingcharacteristics, and design of the pallet 10 or skid 20 beingretrofitted. In addition, any drive wheel assembly 30 or free wheelassembly 40 may be engineered to be either fixed or steerable dependenton the specific size, physical shape, material, loading characteristics,and design of the pallet 10 or skid 20 being retrofitted. The method ofretrofitting such a conventional pallet 10 or skid 20 may be easily andcheaply incorporated without significant change to current conventionalwood, metal, paper, or plastic pallets.

Rather than retrofitting a conventional pallet 10, a driven pallet 100can be manufactured to take the place of a conventional wooden, metal,paper, or plastic pallet 100 commonly seen in a manufacturing orwarehouse operation. The body of the pallet 10 supports the material tobe transported as well as a power source 60, power source rechargecircuitry, as may be shown by items 1020 and 1070 in FIG. 11, and acombination of one or more drive wheel assemblies 30 and/or free wheelassemblies 40.

In another preferred embodiment, free rolling wheel assemblies 40consist of freewheel braces 44 holding caster wheels 48 that arepivotally mounted to battery holder 42. Swiveling wheel section 41 allowskid 200 to be turned easily while all of the drive wheel assemblies 30remain on the ground. Additionally, a load cell or other sensor can beattached to pallet/skid 100/200 along with associated electronics sothat net, tare, and gross weight can be displayed and printed along withtime and date of weighing.

In yet another embodiment, slits may be cut into upper deck 14 ofconventional pallet 10/20 creating additional channels 15 in which drivewheels 38 of a similarly designed pallet 10/20 may rest, allowing forthe stable stacking of driven pallets/skids 100/200 onto a similarlydesigned pallet 10 or skid 20.

Other types of motors 50 such as gearmotors, brushless motors, orstepping motors may also be used. Additionally, motors 50 may be ratedat other voltages such as twelve volts or thirty six volts and may notcontain a gearhead. It will be understood by those skilled in the artthat other types of power sources 60 may be used such as deep cycle,lithium ion batteries. Additionally, the numbers of batteries requiredmay vary. Furthermore, batteries may be rated at other voltages such assix, twenty-four, or thirty-six volts.

It will be appreciated by those skilled in the art that many variationsof the DLC 100/200 are possible without departing from the spirit andscope of the disclosed embodiments. For example, the number of drivewheel assemblies 30 and free-rolling wheel assemblies 40 required inorder to move the pallet/skid 100/200 forward, backward, left, or rightat a desirable speed will vary and is dependent on the specific size,physical shape, material, loading characteristics, and design of thepallet being either retrofitted or manufactured.

With reference to the illustrative embodiment of FIG. 10, a DLC such aspallet/skid 100/200 may comprise rotatable drive wheels 38 and wheelframes 31 coupled to the pallet 10 or skid 20 and one or more free wheel48 coupled to wheel bases 44 rotatably coupled to bodies 42 which arecoupled to pallet 10 or skid 20. Motors 50 may be coupled to either ofpallet 10 or skid 20 and/or wheel frame 31 may be electrically coupledto one or more power sources 60, as described herein in otherillustrative embodiments. According to the illustrative embodiment ofFIG. 10, motors 50 may be electrically coupled via control circuitry 81to control unit 80 for controlling signals sent to motor drive circuitryand motor 50 from power source 60. An exemplary controller 80 maycomprise a directional control 82 and one or more operative controls 84,86, and 88. An exemplary directional control 82 may be a joystick, a keypad, a touch screen, or a scrolling dial. Operative controls 84, 86, and88 may be “ON” or “OFF” buttons, may activate a sound or visual signalduring operation of DLC 100 or 200, may change a function of operationof motor 50, power source 60, or a combination of motors and powersources. Alternatively, operative controls for any of the components ofDLC 100 or skid 200 may be directly or indirectly located on or withinthe DLC 100/200. Alternatively, an exemplary power source 60 accordingto the illustrative embodiment of FIG. 10 may be electrically coupledvia control circuitry 91 to a control unit 90. Like control box 80,control unit 90 may comprise directional control 92 and operativecontrols 94, 96, and 98. Control unit 90 may have the same or similarfunctions and operates connections as control unit 80.

In a preferred embodiment, a controller may comprise a series ofindividual push-buttons in a matrix to form a keypad. Each button may bededicated to a different pallet movement, for example, a buttondedicated to sending a “forward” signal to the motors 50 attached to thedrive wheel assemblies 30 and a button dedicated to sending a “backward”signal to the motors 50 attached to the drive wheel assemblies 30.

Further according to the preferred embodiment, an executed command maybe displayed on a seven segment, light emitting diode display, forexample, a dot matrix display illuminating the letters of the words“FWD” for the forward signal execution and “BWK” for the backward signalexecution. Accordingly, such a preferred embodiment of a controller 80may be coupled to DLC 100/200 via a ribbon cable. As per this preferredembodiment, a microprocessor is used to determine the keypad buttonbeing pushed by the operator, light up the correct command on the sevensegment or dot matrix LED display, and implement the command. Use ofpulse width modulation (PWM) may be used to communicate externally toand from the microprocessor via a card cage electronic holder coupled tothe DLC 100/200 for the microprocessor electronics and PWM circuitry.Alternatively, an 8051 microcontroller may be used for internal PWMcommunications.

In another preferred embodiment, controller 80 may include an actualkeypad to control the DLC 100/200. In this preferred embodiment, controlelectronics that may have been stored in a card cage electronic holderon the DLC 100/200 may be moved to the controller or control box 80.According to this preferred embodiment, digitized commands for movingthe device forward or backward may result in the display of “FWD” and“BWK”, for example, on a dot matrix LED display within control box 80.Motor control circuitry 1030 and 1040 according to this preferredembodiment could be designed using a relay motor drive printed circuitboard. Such exemplary relay motor driver boards may be provided for eachmotor 50 coupled to a driven wheel assembly 30 in or around the lowerdeck/underside of DLC 100/200.

In the illustrative embodiment of FIG. 11, an exemplary control unitschematic 80 or 90 may be shown. As shown in FIG. 11, directionalcontrol 82/92 may be a group of potentiometers 1005, 1006, whosevariation in resistance is communicated as signals to motor cards 1030and 1040, respectively. Operative controls 84, 86, or 88 and 94, 96, or98 may be circuit breaking buttons 1008, 1007, and 1009 whose closing ofthe circuit permits either activation of brakes, visual or audible signs(e.g., siren 1010), on-off activation (e.g., switch 1007) or otherpotential activities which are readily programmable by persons ofordinary skill in the art.

In a preferred embodiment, controller 80/90 contains a safety horn 1010,safety horn push button switch 1009, On-Off switch 1007, and brake pushbutton 1008. Safety horn 1010 is activated while safety horn push buttonswitch 1009 is depressed. Power for activating safety horn 1010 isreceived through direct connection by way of umbilical cable 81/91.Deactivation of on-off switch 1007 or brake push button 1008 sends asignal to motor drive circuitry 1030 and 1040 commanding the motors tocease rotating drive wheels 38. Through pulse width modulation anaverage value of voltage and current is applied to drive wheels 38 at afrequency of 21.77 kilohertz as long as brake switch 1008 is closed andOn-Off switch 1007 is closed. If either switch becomes open or umbilicalcable 81/91 is disconnected, the error condition is detected at 1050 and1060 by motor controller card 1030 and 1040, respectively, and allmotors 50 cease to rotate drive wheels 38.

Control circuitry 81/91 may be leads from the joystick to the variousmotor cards disposed within or near motors 50. As illustrated in FIG.11, power source 60 may comprise one or more batteries or cells,suitable for driving motors 50 for the particular application. Asdisclosed herein, in the case of a rechargeable power source 60, a diodeor similar current restrictive element 1020 may be used to supplyrecharge voltage across power source 60 from a recharge source 1070 suchas an outlet or generator (not shown). Exemplary control circuitry 81/91from control unit 80/90 may therefore couple electrically to both powersource 60 and motors 50. Alternatively separate controllers 80 and 90may be employed depending on the circumstances.

Also, control unit 80/90 containing directional device 82/92 may includea pointing device other than a joystick such as switches. Alternatively,control circuitry 81/91 may be wireless using a radio frequency,infra-red, touch tone, voice activated, or other electronic link such asa GPS signal or an application running on a cell phone, smart phone, orcomputer-like device in order to control movement of DLC 100/200. Inaddition, net, tare, and gross weight can be displayed on the controlbox or on the body of the pallet itself

In a preferred embodiment, control unit 80/90 includes analog joystick82/92 and interfaces with coiled umbilical cable 81/91. Control unit80/90 is constructed from a phenolic instrument case and measures on theorder of 3.75 inches by 6.25 inches by 2 inches. Instrument cases ofthis type are sold by Keystone Electronics Corporation of Astoria, N.Y.Analog joystick 82/92 is manipulated under operator control in order tocommand the DLC 100/200 forward, backward, left, or right at a desirablespeed. The body of analog joystick 82/92 is rotated forty-five degreesbefore being physically mounted within control unit 80/90.

In another preferred embodiment, analog joystick 82/92 consists of two5000 ohm potentiometers 1005 and 1006. Pivoting the position of thejoystick varies the amount of resistance in each potentiometer therebytranslating the joystick's physical position into an electrical signal.Thus, the amount of pulse width modulation applied to motors 50 isprecisely controlled through direct human manipulation of analogjoystick 82/92. Coiled umbilical cable 81/91 is an eight position sevenfoot long modular cable. Modular cables of this type are sold by AssmannWSW Components of Tempe, Ariz. Umbilical cable 81/91 provides a directelectrical connection between joystick 82/92 and motor drive circuitry1030 and 1040. Motor drive circuitry 1030 and 1040 include model number24v12a motor controller printed circuit card manufactured by PololuCorporation of Las Vegas, Nev. The printed circuit cards 1030/1040perform bidirectional control of brushed direct current motors 50.Initial setup of the printed circuit card is performed through a Windowsinterface via a universal serial bus (USB) link. The printed circuitcard uses the technique of pulse width modulation in order to controlthe amount of power applied to rotate wheels 38. In addition, the errorlines 1050 and 1060 of both motor drive circuitry cards 1030 and 1040,respectively, are tied together so that all motors are commanded to stopwhen either card experiences an error. Each printed circuit card cansupply a continuous current of twelve amperes without a heat sink anddirectly interfaces with analog joystick 82/92.

In a preferred embodiment, the power source 60 includes four twelvevolt, twenty-six ampere-hour self-contained gel type rechargeablebatteries. Each battery measures on the order of 6.5 inches by 7 inchesby 5 inches. Batteries of this type are sold by the Power-SonicCorporation of San Diego, Calif. Each battery is securely held in placewith a battery holder (or power source cradle 42 and recharged by way ofbattery recharge circuitry 1020 and 1070. In a preferred embodimentaccording to the illustrations of FIG. 11, power source 60 may comprisetwo pairs of twelve volt batteries connected in series with each pair ofbatteries then connected in parallel in order to supply operatingvoltage for two pairs of direct current twenty-four volt motors 50 thatare connected in parallel. As shown in the illustrative embodiments inFIGS. 5, 7, 8A, 8B, 8C and 8D, motors 50 are securely mounted to thesame side 12 of pallet 10 or skid 20. Each battery is securely fixed tolower deck 18 of pallet 10 or underside of skid 20 in a suitable cradle42.

In yet another preferred embodiment, motor drive circuitry card 1030 and1040 is a twenty-four volt Pololu simple motor controller. Each motordrive circuitry card 1030 and 1040 is electrically connected to driveone direct current twenty-four volt motor 50.

Exemplary motor card 1030 may comprise numerous inputs 1052, 1053 and1054 for receiving signals generated at joystick 82/92 and output 1050for generating an error signal and stopping motor 50 when something isgoing wrong with the controller. According to the illustrativeembodiment of controller circuitry in FIG. 11, motor card 1030 may haveinputs from potentiometer 1005 for a negative potentiometer signal at1052, a positive potentiometer signal at 1053, an output from thepotentiometer 1054, and an error signal at 1050. According to theillustrative embodiment, potentiometer signals at 1052, 1053, and 1054may also serve a feedback function for the operator's use of motors 50coupled to one or more of the motor drive circuitry cards 1030/1040.Thus, if the pallet/skid 10/20 is not traveling at a desirable speed orin a desirable direction, an operator may correct speed and direction ofthe pallet/skid 10/20 via appropriate operation of control unit 80/90.

In accordance with the exemplary embodiments illustrated by FIG. 11, asmotors are supplied power from power source 60, motor card 1030 outputsa pulse modulated signal into 1032 and 1033. Motor card 1030 receivessignals from power source 60 via 1034 and is grounded via 1035. Similarto operation of potentiometer 1005 with motor card 1030, potentiometer1006 operates with motor card 1040 to provide negative and positivepotentiometer signals 1062 and 1064, respectively, and also an outputpotentiometer signal 1063. An error signal is communicated from motorcard 1040 at 1060 and which is ultimately connected to motor card 1030to stop all motors in the event an error is detected. Similar to themotors 50 coupled to motor card 1030, motors 50 coupled to motor card1040 also provides an output, such as pulse width modulation (PWM), to1042 and 1043. Motor card 1040 receives voltage from power source 60 via1044 and is grounded via 1045.

While the illustrative control circuitry illustrated in FIG. 11 may beone form of controlling exemplary motors 50 and exemplary power sources60, other methods of sending signals to motors to control movementswhile responding to changes in activity are known and understood bypersons of ordinary skill in the art. For example, motor drive circuitrymay be installed on DLC 100/200 for the control and transmission ofsignals to the various moving components of the DLC 10/20, for examplemotor cards 1030 and/or 1040. Further, while control circuitry 81/91 maybe embodied in hard wires and cables between controller 80/90 and pallet100 or skid 200, control circuitry 81/91 may also be embodied bywireless connections such as infrared, radio wave, Bluetooth or802.11g/b/n. Those skilled in the art would understand other suitablewireless technologies that provide equivalent functionalities to theanalog technologies provided for by these disclosures.

In a preferred embodiment, a manufactured driven skid 200 includes motorcontrollers 1030 and 1040, control unit 80, power source 60, two drivewheel assemblies 30, and two free rolling caster wheel assemblies 40.Motor controllers 1030 and 1040 may be printed circuit cardsmanufactured by Pololu Corporation of Las Vegas, Nev. and may permitbidirectional control of brushed direct current motor 50. Preferably,the body of skid 20 may support the material to be transported and maybe constructed from one eighth inch thick aluminum diamond plate cut inthe shape of an octagon and measures twenty-four inches by twenty-fourinches. The manufactured driven skid 200 will fit through a standardUnited States residential door having a width of thirty-six inches.Preferably, power source 60 consists of two twelve volt twenty-sixampere-hour sealed rechargeable gel type batteries connected in seriesas shown in FIG. 11.

In a preferred embodiment, two pairs of fixed drive wheel assemblies 30utilizing 36-volt gearmotors 50 will move a pallet 100 load weighingslightly more than 1000 pounds at three miles per hour on a flat surfacefor 3 hours before battery recharging is required.

In an exemplary method for constructing a pallet/skid 10/20 to bedriven, a first step may include selection of a desired shape for thepallet/skid 10/20. In one aspect, a retrofitting of a plastic/woodpallet 10 may be limited by predetermined dimensions, such as, forexample, those found in the Uniform Standard for Wood Pallets, NationalWooden Pallet and Container Association, Alexandria, Va. In anotheraspect, an exemplary pallet/skid 10/20 may be needed to fit through astandard interior door with dimensions between approximately 30 inchesto 34 inches in width or both interior and exterior doors, in which casethe dimensions for exterior doors will usually be wider. An exemplaryshape for an exemplary pallet/skid 10/20 may be an octagon which may beformed of eight interior angles at 135 degrees. An exemplary octagonskid 20 may have all its eight sides being 10 inches in length and anapothem of approximately 12.0711 inches.

In an exemplary method for constructing a pallet/skid 10/20 to bedriven, a second step may include selection of driven wheel assemblies30 and free wheel assemblies 40. Considerations for selection of thedriven wheel assemblies 30 and free wheel assemblies 40 may include, butare not limited to, the following: maximum required pallet/skid 10/20load, maximum required pallet/skid 10/20 load at the maximum desiredspeed, a desired maximum amount of time of load bearing, the amount oftime before one or more power sources 60 require replenishment, e.g.,recharging of batteries, and surface on which pallet/skid 100/200 isexpected to travel.

In a preferred embodiment of the aforementioned method, a designconsideration may include DLC 100/200 stability. According to thispreferred embodiment, a group of four drive wheel assemblies 30 may beselected to provide enhanced stability. In another preferred embodimentof the aforementioned method, a design consideration may include cost ofthe DLC 100/200. Additionally, as part of the design consideration, costis reduced if the number of driven wheel assemblies 30 is reduced.According to the preferred embodiment of a method where an octagonshaped skid 20 is selected, two driven wheel assemblies 30 and two freewheel assemblies 40 may be coupled to the skid 20.

In an exemplary method for constructing a pallet/skid 10/20 to bedriven, a third step may include identifying the force required to moveDLC 100/200 on a specific type of surface while holding a load.According to one aspect of this third step of the exemplary method, DLC100/200 may be tethered to a stationary object and subjected to testingutilizing instrumentation known to those skilled in the art to measurethe force required to move a particular load placed upon the DLC100/200. For example, a DLC 100/200 may be loaded with a maximum weight,placed on a surface on which the DLC is expected to travel, and thenmeasured by use of a spring scale an amount of force to overcomefriction between the drive wheel assemblies 30, free wheel assemblies40, and the surface.

According to the preferred embodiment of an octagon-shaped driven skid200, a required force for moving a loaded, driven skid containing twodriven wheels and two free wheel assemblies on a concrete surface may beexperimentally determined to be related by the following equation:

F≈Load/20;

where “F” is the force in pounds required to overcome friction betweenthe two drive wheel assemblies 30, two free wheel assemblies 40, and theconcrete surface of an exemplary octagon-shaped driven skid 200, “Load”is the weight in pounds of whatever is to be placed on and moved by anexemplary octagon-shaped driven skid 200.

According to the exemplary method for constructing a pallet/skid 10/20to be driven, a fourth step may include determining an amount of torqueto be generated by each drive wheel assembly 30 to move a load atop DLC100/200. In an exemplary method, the torque required is based on thereading obtained on the spring scale and wheel radius.

According to the exemplary method for constructing a pallet/skid 10/20to be driven, a further step in conjunction with the fourth step or as aseparate fifth step may include selection of a drive wheel 38 radius.According to this exemplary method, a larger drive wheel 38 radius mayrequire greater torque and a more powerful motor 50 in order to rotatedrive wheel 38. However, a larger drive wheel 38 radius may also providegreater traveling distances for the DLC 100/200 for each revolution ofthe drive wheel 38.

In a preferred embodiment, of the octagon-shaped driven skid 200, an 8inch diameter drive wheel may be selected and the torque required perdrive wheel determined by the following calculations:

T≈(r*F)/n;

where “T” is the torque required in foot-pounds for each n drive wheel38 of “r” radius in feet. “F” is the measured force in pounds asmeasured on the spring scale to move the pallet and its load.

According to the exemplary method for constructing a pallet/skid 10/20to be driven, a further step may include identification of maximum speedof travel of an exemplary DLC 100/200. A preferred target speed may beapproximately the speed of human walking, such as, for example, 3 milesper hour.

A further step of an exemplary method for constructing a pallet/skid10/20 to be driven may also include optimizing the amount of torque persecond to be provided to each drive wheel 38 from motor 50 to achieve adesired target speed.

In a preferred embodiment, an optimal torque per second to be applied toeach wheel n of a two drive wheel, octagon-shaped driven skid 200 may berelated according to the following equation:

“T” per second=(maximum desired target speed)*(2)*(π)*(required torque);

where “T” is the torque required in foot-pounds per second for each ndrive wheels 38 having a maximum desired target speed in revolutions persecond and a required torque in foot-pounds for each n drive wheels 38so that friction is overcome between the two drive wheel assemblies 30,two free wheel assemblies 40, and the concrete surface of an exemplaryoctagon-shaped driven skid 200,

A further step of an exemplary method for constructing a pallet/skid10/20 to be driven may also include optimizing the motor 50 to meet thedrive requirements of the DLC 100/200. An exemplary 24 volt motor fromLesson Corporation may supply 15 inch-pounds of torque at 300 RPM andrequires 3.8 amps. Such an exemplary motor 50 rotating each drive wheel38 may be used to move 400 pounds at 3 miles per hour using the 8 inchdiameter wheels on a driven, octagon-shaped skid 20.

In conjunction with motor 50 selection, the exemplary method may alsoinclude selection of power source 60. According to an exemplary powersource selection step, optimization of power source 60 may includeselecting a power source having the greatest number of ampere hourspossible contained in the smallest and/or lightest specificationsavailable.

While the above is an exemplary method for constructing a pallet/skid10/20 to be driven, each of the steps may be repeated and re-ordered asrequired and/or the results of each step be calculated through iterativeanalysis.

While the system and method have been described by way of exampleembodiments, it is understood that the words which have been used hereinare words of description, rather than words of limitation. Changes maybe made, within the purview of the appended claims without departingfrom the scope and spirit of the system and method in their broaderaspects. Although the system and method have been described herein withreference to particular interrelated structures, interrelated materials,and interrelated embodiments, it is understood that the system andmethod is not limited to the particulars disclosed.

I claim:
 1. A hand-operated controller system for a driven loadableconstruct, comprising: a plurality of control circuit components each ofwhich transmits a discrete signal as a result of physical interactionbetween a hand-operated directional control and the plurality of controlcircuit components; connection circuitry for communicating the discretesignals from the plurality of control circuit components to a DC motorcard coupled to at least one motor disposed on the loadable constructand to which at least one drive wheel disposed on the loadable constructis operatively connected.
 2. The controller of claim 1, furthercomprising at least one operative control circuit configured to controloperation of the loadable construct.
 3. The operative control circuit ofclaim 2, wherein the at least one operative control circuit connects toat least one power source, at least one motor, or a combination of atleast one power source and at least one motor.
 4. The at least oneoperative control circuit of claim 2, comprising at least one designatedbutton designated for sending a signal related to different loadableconstruct operations.
 5. The at least one operative control circuit ofclaim 2, comprising a plurality of designated buttons each of whichbeing configured to send different signals related to different loadableconstruct operations.
 6. The plurality of designated buttons of claim 5,wherein each designated button sends signals through the connectioncircuitry to at least one power source, at least one motor, at least onedisplay means, or a combination thereof.
 7. The directional control ofclaim 1, wherein the directional control comprises a joystick, a switch,a key pad, a touch screen, a scrolling device, or an application runningon a machine from the group consisting of computers, mobile devices,interactive displays, and combinations thereof.
 8. The directionalcontrol of claim 1, wherein the directional control is coupled to aplurality of DC motor cards disposed on the loadable construct via theconnection circuitry.
 9. The connection circuitry of claim 1, furthercomprising circuitry for wirelessly communicating signals from at leastone component of the plurality of control circuit components to at leastone motor disposed on the loadable construct.
 10. The connectioncircuitry of claim 9, wherein the wirelessly communicated signals areinfrared, Bluetooth, radio wave, GPS, 802.11g/b/n, or a combinationthereof.
 11. The plurality of control circuit components of claim 1,wherein at least one of the plurality of control circuit componentstransmits signals for controlling torque to apply to the at least onedrive wheel.
 12. The plurality of control circuit components of claim11, wherein the signals for controlling torque to apply to the at leastone drive wheel result from placement of a load on the loadableconstruct.
 13. A voice-activated controller system for a driven loadableconstruct, comprising: a plurality of control circuit componentsreceiving inputs from a voice-activated directional control; connectioncircuitry for communicating the signals from the plurality of controlcircuit components to at least one motor disposed on the loadableconstruct and to which at least one drive wheel disposed on the loadableconstruct is operatively connected.
 14. The controller of claim 13,further comprising at least one operative control circuit configured tocontrol operation of the loadable construct.
 15. The operative controlcircuit of claim 14, wherein the at least one operative control circuitconnects to at least one power source, at least one motor, or acombination of at least one power source and at least one motor.
 16. Theat least one operative control circuit of claim 14, comprising at leastone designated button designated for sending a signal related todifferent loadable construct operations.
 17. The directional control ofclaim 13, wherein the directional control is coupled via the connectioncircuitry to at least one motor card disposed on the loadable construct.18. The connection circuitry of claim 13, further comprising circuitryfor wirelessly communicating signals from the control circuit to atleast one motor disposed on the loadable construct.
 19. The directionalcontrol of claim 13, wherein the directional control is one or more of amobile device or an application running on a machine from the groupconsisting of computers, mobile devices, or interactive displays. 20.The connection circuitry of claim 10, wherein the wirelesslycommunicated signals are infrared, Bluetooth, radio wave, GPS,802.11g/b/n, or a combination thereof.